Dimensional foam brassiere

ABSTRACT

A brassiere garment having a pair of cup portions, each cup portion with an inner foam cup molded generally to the shape of the wearer&#39;s bust, and an outer fabric layer overlying the foam cup. Each foam cup has a first lower portion comprising a foam ply that is substantially inelastic in its lateral dimension, and a second upper portion that exhibits one or more of a lighter weight, lower density, greater elasticity and lesser thickness than the lower first portion. The lower first portion and upper second portion join with one another along a line generally traversing the foam cup from a lower and inward side of the foam cup and extending upward and laterally outward in direction. In certain embodiments, the line along which the lower first portion and upper second portion are joined with one another generally extends to or through the apex of the foam cup. Further, a pair of chest bands extends laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 61/037,038, entitled “Lightweight Brassiere” and filed 17 Mar. 2008 by the present inventive entity (Attorney Docket No. PP/1708-106). This application is related to the concurrently filed non-provisional application entitled “Lightweight Brassiere” (Serial No. unassigned) by the same inventive entity (Attorney Docket P/1708-124) which itself claims priority of the same provisional application. The complete disclosure of both applications is hereby incorporated by their reference for all purposes.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

The present disclosure relates to the field of female intimate apparel, and more particularly to a brassiere that achieves superior comfort for the wearer.

SUMMARY OF THE INVENTION

Provided according to the present disclosure is a brassiere garment having a pair of cup portions, each cup portion with an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup. The cup portions are connected with one another by a bridge portion generally at a vertical centerline of the brassiere. Each foam cup has a first lower portion comprising a foam ply that is substantially inelastic in its lateral dimension, and a second upper portion that exhibits one or more of a lighter weight, lower density, greater elasticity and lesser thickness than the lower first portion. The lower first portion and upper second portion join with one another along a line generally traversing the foam cup from a lower and inward side of the foam cup and extending upward and laterally outward in direction. In certain embodiments, the line along which the lower first portion and upper second portion are joined with one another generally extends to or through the apex of the foam cup. Further, a pair of chest bands extends laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end thereof.

Furthermore, each foam cup further can comprise an outer portion extending generally inward from an outer lateral extent of each cup, each outer portion joining the respective lower potion along a line generally traversing the cup upward and inward from a lower and outward side of the cup, and extending upward and inward in direction. Each outer portion may join the respective upper potion either along a line generally traversing the cup upward and inward from a lower and outward side of the cup, and extending upward and inward in direction, or along a line generally traversing the cup upward and inward from a lower and inward side of the cup, and extending upward and outward in direction. In particular embodiments, the lower, upper and/or outer portions are joined with one another by sonic joining.

Each lower first portion may include an inelastic fabric layer bonded thereto, the inelastic fabric layer being one or more of marisquette, taffeta, or nylon, or a woven or non-stretch knit construction. An upper second portion of each foam cup has an elongation of about 50%. The foam cup may be a polyurethane foam.

In certain embodiments, the outer fabric layer comprises a single unitary panel overlying each foam cup, or comprises multiple parts, preferably joined to each other by a sonic finish. The multiple parts may correspond in size and shape to their respective underlying lower first portion and upper second portion of each foam cup, but need not.

According to a certain embodiment of the present disclosure, A brassiere garment comprises pair of cup portions, each having an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup, each foam cup having a first lower portion with a foam ply having a generally inelastic fabric bonded thereto, and a second upper portion having an elastic fabric layer bonded thereto. The lower first portion extending from a point at a lower and inward side of the foam cup and extending upward and laterally outward in direction. A brassiere garment according to the present disclosure may include a pair of straps, one each connecting each of the respective chest bands to its adjacent cup portion, with each strap having a wider portion thereof located generally over the wearer's shoulder in ordinary use.

It is an object of the present disclosure to provide a brassiere that gives intended support to the user while increasing comfort by its structure and/or shape, and also by reduced weight. In particular a two-part cup includes a two-part foam pad with a lower part having more resiliency for added support, while an upper part has greater elasticity for improved comfort. On the other hand, use of a spacer fabric in the brassiere cup, or in its place a resilient and oriented fiber-fill material can provide the desired support at a minimum weight. Additional features include use of Ti-alloy materials in place of traditional steel components, a narrower fabric channel for the underwire, and elimination of stitching by using sonic seal wherever possible.

BRIEF DESCRIPTION OF THE DRAWING(S)

These and other features, benefits and advantages of the present disclosure will become apparent from the following description of the disclosure and the appended claims, which refer to the accompanying drawings, wherein like reference numerals refer to like features across the several views, and wherein:

FIG. 1 illustrates a front elevation view of a lightweight brassiere according to a first embodiment of the present disclosure;

FIG. 2 illustrates a cross-sectional view taken along line 2-2 of FIG. 1;

FIG. 3 a illustrates a rear elevation view of a second embodiment of the present disclosure;

FIG. 3 b illustrates a front elevation view of the second embodiment in FIG. 3 a;

FIG. 3 c illustrates a front elevation view of a further alternate embodiment; and

FIG. 3 d illustrates a rear elevation view of a fourth alternate embodiment of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Referring now to FIG. 1, illustrated is a front elevation view of a lightweight brassiere, generally 100, according to a first embodiment. Brassiere 100 is characterized by a two-part cup construction 1, 2. A cut seam 7 connecting the two parts of the cup can be sewn and/or sealed by a sonic finishing technique. Seam 7 is at an angle to the horizontal plane as illustrated in FIG. 1, and traverses the two-part cup 1, 2 from generally the center of the brassiere A upward and outward across the cup. The seam 7 traverses the opposite cup in a mirror-image manner. Included in the embodiment of FIG. 1, the shoulder strap 8, is integral with the cup 9.

FIG. 2 illustrates a cross-sectional view through the two-part cup 1, 2, taken along line 2-2 of FIG. 1. The two part cup comprises an outer fabric layer 110, in two parts, upper fabric layer and lower fabric layer 101, 102, respectively. As an example only, either or both may be satin, though lace, cotton, synthetic fiber, or nearly any fabric may be substituted. Upper and lower fabric parts 101, 102 are joined at seam 103, in this case by a sonic finish, though alternately or additionally, they may be sewn. In a further embodiment, the outer fabric may comprise a single-piece seamless fabric panel. Optionally, the outer cover fabric may be bonded to the foam pad 112 (and any optional intervening layers), or simply overlie the foam pad 112 without bonding thereto, either before or after an optional molding step in the production of the brassiere.

The cup of brassiere 100 also comprises an inner foam pad 112, in upper and lower parts, 104, 105, respectively. The upper and lower parts 104, 105 are joined together at seam 106, also preferably by sonic finish. The seam 106 is preferably parallel with seam 103 and more preferably aligned with and adjacent to seam 103, though other embodiments of the present disclosure can differ. Seam 106 (and optionally 103) can begin at a lower and respective inward, with reference to a vertical centerline of the brassiere 100, quadrant of each cup 9, and traverse the cup 9 in a direction of the apex 10 of the cup 9, generally upward and outward. The apex is adjusted by sizing, but in general, for a size 34B, will be 3.25″ measured vertically from the bottom of the cup 1, with an incremental increase for each size step increase, for example 0.25″. This embodiment may be adjusted to any size, however, it is considered particularly well-suited to standard sizes 32-38B, and 32-36C.

Optionally, the foam pad 112 or at least the upper or lower part 104, 105, may include an inner and/or outer fabric laminate layer 107, 108, respectively. Inner and outer in this sense refers to the brassiere as it is intended to be worn by a user. The upper and lower parts 104, 105 of inner foam pad 112 have differing material characteristics. The lower part 105 is to provide adequate support to the wearer, while the upper part 104 is to be more flexible for comfort. To achieve this, the two sections are formed to have differing material properties. The lower portion 105 may be thicker, more dense, and/or have reduced elasticity, in order to provide the desired support. In a preferred embodiment, the lower portion 105 is substantially inelastic, i.e., dimensionally stable, within the plane defined by the molded shape of the inner foam pad 112 when subjected to the loads in its ordinary use which it is expected or designed to withstand. In one embodiment this feature is achieved by bonding an inelastic fabric to the lower part 105, e.g., as inner and/or outer fabric layer 107, 108. Suitable non-elastic fabrics include marisquette, which provide lightweight resistance to stretching, though taffeta, nylon, or other fabrics may be used, including those having woven or non-stretch knit construction. In comparison, upper part 104 may include an elastic knit fabric as either layer 107 or 108, or both, if both are present in the particular embodiment. An elastic fabric 107 and/or 108 laminated to a foam pad within upper part 104 would permit the elasticity of the foam to enhance user comfort.

The thickness of the lower part 105 may be adjusted as desired to provide more or less lift to the wearer's anatomy, thereby inducing an optional enhancement of the wearer's cleavage. By contrast, the upper part 104 will be comparatively thinner, less dense, and/or more elastic than the lower portion 105. In one embodiment upper part 104 exhibits an elongation of 50%, i.e., a 1-inch section stretches to 1.5 inches under a predefined test load (for example, ASTM D3574, or Polyurethane Foam Association). The foam pad 112 may be constructed of a polyurethane foam, or any cellular foam for which the characteristics of weight, density, thickness and elasticity can be controlled. Polyurethane foam of 38 kg per cubic meter (kcm) density is suitable in certain embodiments, though specific material and/or density may be altered within the scope of the present disclosure.

In addition to the two-part cup construction described above, the brassiere 100, and particularly the two-cup 1,2 thereof, may be molded after or during construction generally to the shape of the user's body for enhanced comfort.

Particular attention is given to the structure of the brassiere cup of the foregoing embodiment. The balance of features of the brassiere according to the first embodiment may be entirely conventional. Alternately, some or several or all of the features described with respect to the following embodiments may be incorporated into the foregoing embodiment, in addition to those specifically described.

Turning now to FIG. 3 a, illustrated is a rear elevation view, i.e., as viewed from an inside with respect to the wearer, of another embodiment of a brassiere, generally 300, according to the present disclosure. The brassiere 300 includes a multi-part cup construction. Cup 301 includes a first lower cup part 303, including a substantially foam pad (not shown). The foam pad part of first lower cup part 303 is comparable to that of lower part 105 described with reference to the prior embodiment. An upper cup part 305 joins to lower cup part 303 along seam 306, preferably by sonic joining. A foam pad underlies upper cup part 305 in a manner similar to the upper part 104 described with reference to the prior embodiment. The cup 301 also includes a laterally outer part 307. Outer part 307 and a respective foam pad (not shown) generally correspond in material properties to lower cup part 303.

Shoulder straps 309 are integrally joined 311 to the cup 301 at outer cup part 307, and feature a wider thickness 311 corresponding to the wearer's shoulders, to distribute the pressure and increase comfort. Straps 309 may also be joined by stitching or ultrasonic welding for convenience of manufacture of to suit a particular design. Chest band 315 in the exemplary embodiment includes a double-layer satin outer portion and a mesh inside layer, again providing enhanced wearer comfort. Chest band 315 is clean-finished at its top and bottom edges with an enclosed elastic band 317. The chest band 315 is finished in a so-called ballet style 323. The neckline and armholes at strap 309 are also finished with an inward bonding for added comfort. Respective cups 301 are joined to one another by bridge portion 319.

Cups 301 are provided with an underwire 321, enclosed in a conventional fabric channel 322, which is optionally finished with two-needle stitching. In certain embodiments, the underwire 321 comprises a lightweight alloy metal, for example a Ti-alloy, offering superior stiffness for a given weight, i.e., enabling lightweight construction. Strap rings 325 that connect the shoulder straps 309 to the chest band 315 may also be of Ti-alloy, as may be strap length adjustment slides 326.

Turning to a front view of brassiere 300 as shown in FIG. 3 b, the cup portion 301 includes an outer cover fabric in three parts, 327, 328, and 329. These generally correspond in size and position to respective underlying cup parts 303, 305, and 307. Fabric cover parts 327, 328 and 329 are preferably joined to one another by sonic sealing along seams 331, 332, but may be sewn or joined by other means.

In yet another embodiment, illustrated in a front elevation view as FIG. 3 c, brassiere 300 a includes a unitary outer fabric layer 340 overlying cups 301, i.e., without seams 331, 332 of the embodiment shown in FIG. 3 b. The embodiment 300 a is otherwise similar to the prior embodiment 300. It is further contemplated that, notwithstanding the three-part cup construction described with reference to FIG. 3 b, an outer fabric layer overlying the cups 301 may be embodied as a two-part construction, in a similar fashion as described with respect to FIG. 1.

In still another embodiment, illustrated in rear elevation view as FIG. 3 d, brassiere 300 a includes cups 301 b, having a multi-part construction. In this embodiment, an upper part 305 traverses the cup from an inward portion upward and outward to a top extent of the cup 301 b. An outer portion 307 b extends inward from a lateral extent, and a lower portion 303 b extends upward from a lower extent. The respective upper, lower and outer portions are otherwise similar to their corresponding section described with respect to brassiere 300 in FIG. 3 b, above.

Although the present disclosure has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present disclosure be limited not by the specific disclosure herein, but only by the appended claims. 

1. A brassiere garment comprising: a pair of cup portions, each having an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup, the cup portions being connected with one another by a bridge portion generally at a vertical centerline of the brassiere; each foam cup having a first lower portion comprising a foam ply that is substantially inelastic in its lateral dimension, and a second upper portion that exhibits one or more of a lighter weight, lower density, greater elasticity and lesser thickness than the lower first portion; the lower first portion and the upper second portion being joined with one another along a line generally traversing the foam cup from a lower and inward side of the foam cup and extending upward and laterally outward in direction; and a pair of chest bands extending laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end.
 2. A brassiere garment according to claim 1, wherein each foam cup further comprises an outer portion extending generally inward from an outer lateral extent of each cup, each outer portion joining the respective lower potion along a line generally traversing the cup upward and inward from a lower and outward side of the cup, and extending upward and inward in direction.
 3. A brassiere garment according to claim 2, wherein each outer portion joins the respective upper potion along a line generally traversing the cup upward and inward from a lower and outward side of the cup, and extending upward and inward in direction.
 4. A brassiere garment according to claim 2, wherein each outer portion joins the respective upper potion along a line generally traversing the cup upward and inward from a lower and inward side of the cup, and extending upward and outward in direction.
 5. A brassiere garment according to claim 1, wherein each lower first portion comprises an inelastic fabric layer bonded thereto.
 6. A brassiere garment according to claim 5, wherein the inelastic fabric layer comprises one or more of marisquette, taffeta, or nylon.
 7. A brassiere garment according to claim 5, wherein the inelastic fabric layer comprises a woven or non-stretch knit construction.
 8. A brassiere according to claim 1, wherein the upper second portion of each foam cup has an elongation of about 50%.
 9. A brassiere according to claim 1, wherein the foam cup comprises a polyurethane foam.
 10. A brassiere according to claim 1, wherein the lower first portion and upper second portion being joined with one another by sonic joining.
 11. A brassiere according to claim 1, wherein the outer fabric layer comprises a single unitary panel overlying each foam cup.
 12. A brassiere according to claim 1, wherein the outer fabric layer comprises multiple parts, joined to each other by a sonic finish.
 13. A brassiere according to claim 12, wherein the multiple parts correspond in size and shaper to their respective underlying lower first portion and upper second portion of each foam cup.
 14. A brassiere according to claim 1, wherein the outer fabric layer comprises a microfiber fabric layer.
 16. A brassiere according to claim 1, wherein the line along which the lower first portion and upper second portion are joined with one another generally extends to or through an apex of the foam cup.
 17. A brassiere garment comprising: a pair of cup portions, each having an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup; each foam cup having a first lower portion comprising a foam ply having a generally inelastic fabric bonded thereto, and a second upper portion having an elastic fabric layer bonded thereto; the lower first portion extending from a point at a lower and inward side of the foam cup and extending upward and laterally outward in direction; and a pair of chest bands extending laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end.
 18. A brassiere garment according to claim 17, further comprising a pair of straps, one each connecting each of the respective chest bands to its adjacent cup portion.
 19. A brassiere garment according to claim 18, wherein each strap has a wider portion thereof located generally over the wearer's shoulder in ordinary use. 